'Going better than it ever did' and 'loads of smoke' could well be overfuelling... Iirc you replaced injectors with correct numbered variety or did you leave alone after leakback test? Have you checked fuel pressure regulator? Have you checked or substituted maf?
The popping noise is often vacuum related, have you tried blanking off the pipe to the solenoid on the side of the airbox as per SiRobb's video?
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